WO2010138993A1 - Modular building system - Google Patents
Modular building system Download PDFInfo
- Publication number
- WO2010138993A1 WO2010138993A1 PCT/AU2010/000647 AU2010000647W WO2010138993A1 WO 2010138993 A1 WO2010138993 A1 WO 2010138993A1 AU 2010000647 W AU2010000647 W AU 2010000647W WO 2010138993 A1 WO2010138993 A1 WO 2010138993A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- panels
- panel
- wall
- holes
- floor
- Prior art date
Links
- 238000010276 construction Methods 0.000 claims abstract description 33
- 239000000463 material Substances 0.000 claims abstract description 32
- 239000004566 building material Substances 0.000 claims abstract description 5
- 239000011810 insulating material Substances 0.000 claims abstract description 4
- 230000013011 mating Effects 0.000 claims abstract description 3
- 230000001413 cellular effect Effects 0.000 claims abstract 3
- 238000009435 building construction Methods 0.000 claims abstract 2
- 239000004567 concrete Substances 0.000 claims description 24
- 230000003014 reinforcing effect Effects 0.000 claims description 7
- 229910000831 Steel Inorganic materials 0.000 description 18
- 239000010959 steel Substances 0.000 description 18
- 238000004519 manufacturing process Methods 0.000 description 14
- 239000004411 aluminium Substances 0.000 description 10
- 229910052782 aluminium Inorganic materials 0.000 description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 238000013461 design Methods 0.000 description 7
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 7
- 239000000395 magnesium oxide Substances 0.000 description 7
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 7
- 239000004698 Polyethylene Substances 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 5
- 238000009415 formwork Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 229920000573 polyethylene Polymers 0.000 description 5
- 230000002787 reinforcement Effects 0.000 description 5
- 239000011800 void material Substances 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 239000011518 fibre cement Substances 0.000 description 4
- 238000005304 joining Methods 0.000 description 4
- 239000002699 waste material Substances 0.000 description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- 238000004891 communication Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 239000011777 magnesium Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000009428 plumbing Methods 0.000 description 3
- 239000004568 cement Substances 0.000 description 2
- 239000004035 construction material Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 239000012779 reinforcing material Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 239000011094 fiberboard Substances 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 229920003041 geopolymer cement Polymers 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
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- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000011505 plaster Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000011178 precast concrete Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
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Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
- E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D27/00—Foundations as substructures
- E02D27/01—Flat foundations
- E02D27/02—Flat foundations without substantial excavation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/16—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material
- E04B1/161—Structures made from masses, e.g. of concrete, cast or similarly formed in situ with or without making use of additional elements, such as permanent forms, substructures to be coated with load-bearing material with vertical and horizontal slabs, both being partially cast in situ
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B7/00—Roofs; Roof construction with regard to insulation
- E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
- E04B7/24—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs being collapsible or retractable, e.g. for transport
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/005—Girders or columns that are rollable, collapsible or otherwise adjustable in length or height
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C3/00—Structural elongated elements designed for load-supporting
- E04C3/02—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces
- E04C3/29—Joists; Girders, trusses, or trusslike structures, e.g. prefabricated; Lintels; Transoms; Braces built-up from parts of different material, i.e. composite structures
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2/8635—Walls made by casting, pouring, or tamping in situ made in permanent forms with ties attached to the inner faces of the forms
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/84—Walls made by casting, pouring, or tamping in situ
- E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
- E04B2002/8676—Wall end details
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B21/00—Means for preventing relative axial movement of a pin, spigot, shaft or the like and a member surrounding it; Stud-and-socket releasable fastenings
- F16B21/09—Releasable fastening devices with a stud engaging a keyhole slot
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
- F16B5/02—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them by means of fastening members using screw-thread
Definitions
- This invention relates to modular building systems incorporating honeycomb grid building panels and novel building solutions for construction purposes.
- the invention also relates to buildings and construction systems employing vertical wall panel elements, .horizontal floor panel elements, horizontal ceiling panel elements and angular roofing panel elements that may use structural benefits of honeycomb grid design.
- the invention particularly relates, but is not necessarily limited, to hollow building panels constructed with high density board or a reinforced board which may be filled with structural materials to meet structural strength, thermal- barrier and acoustic-barrier standards, and to buildings and construction systems employing such panels.
- Additional core elements may be slidably mounted between the top and bottom and are easily adjustable to a desired height to accommodate electrical outlets and switches.
- the core elements are retained within the frame members by keepers extending inwards from the frame members to ride in slits in the core members!
- the sliding core members must be secured by punching through side walls of the frame member.
- This system may also include upper and lower tracks.
- Boyle is also directed to dry wall construction.
- the core elements must be slid along the length of the frame members and, in relation to the intermediate core elements, are not self-retaining. They must be punched into position.
- U.S. Pat. No. 3,900,996 (“Yohe”) discloses a hollow wall structure with wall panels having slits in opposite vertical edges which slidably receive channel shaped margins of elongated fastener strips. Clip elements are also provided to lock a panel in place with a channel shaped wall stud. This system is relatively complex and is designed for demountable hollow wall construction.
- WO 96/27057 (“Chicago Metallic”) discloses structural elements for walls comprising clamping profiles and connecting pieces slidable in the clamping 5 profiles. Resilient wings of the clamping profiles engage flanges extending from a panel. Connecting pieces may then be used to connect clamping profiles. This is a relatively complex arrangement for use in dry wall formation.
- One embodiment of the present invention provides a building panel which can be 0 manufactured in a range of heights, widths and/or thicknesses from a minimum number of different components.
- a preferred embodiment may also provide such a panel which has minimal thermal bridging, for improved thermal-barrier characteristics.
- the preferred embodiment may provide a building panel which minimizes corrosion by separating dissimilar metals.
- the building panel may use off-cuts from the facing sheets and for connector elements in the building panel to minimize waste.
- the invention resides in a honeycomb grid for use in building panel construction.
- the building panel comprises a slotted perimeter frame to be bonded and/or fastened to the inner faces of associated facing sheets, vertically and horizontally spaced opposed grid connectors forming a honeycomb grid structure.
- the grid connectors may incorporate dovetail or similar pattern to engage a rebate formed on the internal surfaces of the high density facing boards .
- the grid connectors are preferably interlocking with fill holes and conduit holes for services.
- the internal connectors can be formed from high density board such as but not limited to magnesium oxide board, fiber cement board, reinforced board or other suitable materials. It is preferable that the internal perimeter connectors be formed from a structural material similar but not limited to reinforced high density board bonded to steel channel.
- the facing sheets are formed of fire- resistant, or fire-retardant materials, such as Magnesium Oxide reinforced board, fibre-cement sheeting, aluminium sheeting, polymer sheeting or the like.
- Facing sheets may have a pre- finished outer face, or be coated with suitable materials such as, but limited to paint, plaster or other coatings or finishes.
- the invention may reside in a new building system incorporating the use of the modular building panels.
- the system will comprise of vertical wall panel elements, .horizontal floor panel elements, horizontal ceiling panel elements and angular roofing panel elements that may use structural benefits of honeycomb grid design.
- the invention resides in a HORIZONTAL FLOOR PANEL construction, the modular floor panel comprising of reinforced precast concrete. This could be prestressed, post tentioned or conventionally reinforced.
- a horizontal floor panel element resides in a honeycomb grid for use in floor panel construction, the floor panel comprising a slotted perimeter steel frame to be bonded and/or fastened to the inner faces of associated facing sheets, vertically and horizontally spaced opposed grid connectors forming a honeycomb grid structure.
- the invention may reside in a building system for use in panel form work for solid filled floors, but unlike prior art, it is not necessary to fill with structural material.
- the structural integrity of the panel is created with the honeycomb grid configuration of connectors.
- the honeycomb grid connectors may be formed from reinforced magnesium oxide reinforced board, medium density f ⁇ berboard, high density fiberboard, fiber cement board, steel, aluminium or other suitable materials.
- the grid connectors may incorporate "dovetail" or similar pattern to engage a rebate formed internally on both .
- the grid connectors are preferably interlocking with fill holes and conduit holes for services. Facing sheets may have a pre-finished outer face, or be adapted to be surfaced eg. by tiles, carpet or other suitable finishes.
- An aperture may be formed in the grid connector element and dimensioned to allow passage of one or both of reinforcing materials, void forms, conduits and utility services such as plumbing, electrical lines and communication lines.
- reinforcement is not integral to structural design due to the honeycomb grid design, but may be used in some areas such as earthquake and high wind areas. If required, hole locations are omitted or installed to direct flow of structural fill material. This allows panels faces to provide permanent formwork, thereby, reducing labor and resources.
- the horizontal floor panel may further comprise perimeter elements having a channel to receive a bottom, sides or top edge of a facing board around the perimeter.
- the perimeter channel elements can be formed by an extrusion of steel, aluminium, polyethylene or as a fabrication of any suitable tensile or reinforced material.
- the perimeter channel elements may have pressed flanges to form a connection to engage internal honeycomb grid connectors on the perimeter of the horizontal floor panel.
- the horizontal floor panel element may comprise one or more "keyhole" locking elements (Figure 27) These may be simple connectors or infill bolts in core fill situation to attached vertical wall panel elements ( Figure 3)
- the horizontal floor panel element may comprise one or more jacks. ( Figure 18, Reference 10)
- the horizontal floor panel element may be prefabricated and modular in sizes to suit house designs and in increments that suit appropriate structural grid connector spacings, or a similar size dictated by structural engineer or testing authority.
- the horizontal floor panel element is the first element to be installed with the use of leveling jacks.
- leveling jacks ( Figure 19, Reference 10) These jacks may be used only as a temporary support to level building floor panel element and hold wall panel elements prior to placement of concrete.
- a concrete perimeter footing may be adopted or a bored pier may be used.
- a screw pile ( Figure 24, Reference 20) may be used, negating need for concrete footing structures. Tie down to the earth is then achieved by connection of screw pile to floor panel element bracket. This arrangement is still leveled with jack system as per previous methods.
- the horizontal floor panel element may be utilized in structural suspended floors.
- the bottom facing sheet may be used as the ceiling of the level below.
- a VERTICAL WALL PANEL element can be use as form work for solid filled walls, but unlike prior art, it is not necessary to fill with structural material- The structural integrity of the panel is created by the bonding of the honeycomb grid connectors to the two facing boards.
- honeycomb grid connectors may be formed from reinforced magnesium oxide reinforced board, medium density fibreboard, high density fibreboard, fibre cement board, steel, aluminium or other suitable materials.
- An aperture may be formed in the grid connector element and dimensioned to allow passage of one or both of reinforcing materials, void forms, conduits and utility services such as plumbing, electrical lines and communication lines.
- reinforcement is not integral to structural design due to the honeycomb grid design, but may be used in some areas such as earthquake and high wind areas. If required, hole locations are omitted or installed to direct flow of structural fill material. This allows panels faces to provide permanent formwork, thereby, reducing labour and resources. Window, door and void openings can then be cut out after fill materials are installed. It is preferable that this removed material is cut up and recycled as granular aggregate for insulation, recycled to manufacture board or recycled to manufacture geopolymer concrete or other suitable materials.
- the vertical wall panel may further comprise end elements having a channel to receive a bottom, sides or top edge of a facing sheet around perimeter.
- the perimeter channel elements can be formed by an extrusion of steel, aluminium, polyethylene or as a fabrication of any suitable tensile or reinforced material.
- the perimeter channel elements may have pressed flanges to form a connection to engage internal honeycomb grid connectors on the perimeter of the vertical wall panel.
- the vertical wall panel element may comprise one or more keyhole locking elements. These may be simple connectors or infill bolts in a core fill situation.
- the vertical wall panel element may have bottom fins open to allow concrete footing placement.
- the vertical wall panel element also incorporates flush mounted clips to allow easy placement of steel reinforcement if required.
- Horizontal steel bar may be used, alternatively, steel or poly fibre concrete may be used. See detail on Figure 16 detailing the clip that positions the reinforcement.
- the vertical wall system (Figure 7 elevation) further comprises one or more vertical structural elements (Figure 21, Reference 4 plan view) to form corners and intersections. These may be manufactured in sheet layers of magnesium reinforced board, or similar high density board or other suitable non compressible material.
- the vertical structural element may incorporate holes to house structural ferrules (Figure 21 , Reference 15 plan view) and various connectors.
- This ferrule may accept simple connectors or concrete anchor connectors ( Figure 21, Reference 14 plan view) for core fill applications.
- a washer may be placed between connector and panel for material separation and ease of construction.
- the building system further comprises more than one type of high density board joist and bearer types. These may be fabricated with dovetailed connectors and teeth bonded connections in pieces of magnesium reinforced board, similar high density board or other building material.
- a composite joist may be manufactured from a high tensile material similar to steel(Figure 22, Reference 17) which may be bonded to high density board ( Figure 22, Reference 18) or similar material to increase the strength of the joist.
- a bearer may be fabricated with dovetailed connectors and teeth bonded connections to form a truss like member in pieces of magnesium reinforced board, similar high density board or other building material.
- One embodiment of the present invention may provide a horizontal floor panel which can be manufactured in a range of lengths, widths and/or thicknesses from a minimum number of different components.
- One embodiment of the present invention may provide a HORIZONTAL CEILING PANEL which can be manufactured in a range of lengths, widths and / or thicknesses from a minimum number of different components.
- the invention resides in a honeycomb grid for use in horizontal ceiling panel construction, the ceiling panel comprising a slotted perimeter steel frame to be bonded and/or fastened to the inner faces of associated facing sheets, vertically and horizontally spaced opposed grid connectors forming a honeycomb grid structure.
- the invention may reside in a building system which uses horizontal ceiling panels, whereby the structural integrity of the panel is created with the honeycomb grid configuration of connectors.
- the honeycomb grid connectors may be formed from reinforced magnesium oxide reinforced board, medium density fibreboard, high density fib re board, fibre cement board, steel, aluminium or other suitable materials.
- the grid connectors may incorporate "dovetail" or similar pattern to engage a rebate formed internally on both facing sheets .
- the grid connectors are preferably interlocking with fill holes and conduit holes for services. Facing sheets may have a pre-finished outer face, or be adapted to be surfaced eg. by paint, or other suitable finishes.
- the horizontal ceiling panel may further comprise perimeter elements having a channel to receive a bottom, sides or top edge of a facing board around the perimeter.
- the perimeter channel elements can be formed by an extrusion of steel, aluminium, polyethylene or as a fabrication of any suitable tensile or reinforced material.
- the perimeter channel elements may have pressed flanges to form a connection to engage internal honeycomb grid connectors on the perimeter of the horizontal ceiling panel.
- the invention may reside in a building roof system to incorporate horizontal ceiling panel element only to provide walking platform, perimeter soffits of building (by overhang) and lined ceiling for dwelling. From this platform, a conventional light weight framed roofing structure may be erected. ( Figure 5, Reference 7a)
- the horizontal ceiling panel may comprise one or more "keyhole' locking elements. These may be simple connectors or may allow the modular ceiling panel elements to "click” and engage to connectors from vertical wall panel elements.
- These horizontal ceiling modules would comprise of ceiling panel element (to satisfy external soffit of dwelling, internal ceiling lining and walking platform for services installation in roof void.
- One embodiment of the present invention may provide an ANGULAR ROOFING PANEL element which can be manufactured in a range of lengths, widths and / or thicknesses from a minimum number of different components.
- the invention resides in a honeycomb grid for use in angular roofing panel construction, the angular roofing panel comprising a slotted perimeter steel frame to be bonded and/or fastened to the inner faces of associated facing sheets, vertically and horizontally spaced opposed grid connectors forming a honeycomb grid structure.
- the invention may reside in a building system which uses angular roofing panels, whereby the structural integrity of the panel is created with the honeycomb grid configuration of connectors.
- the honeycomb grid connectors may be formed from reinforced magnesium oxide reinforced board, medium density fibreboard, high density fibreboard, fibre cement board, steel, aluminium or other suitable materials.
- the grid connectors may incorporate 'dovetail" or similar pattern to engage a rebate formed internally on both facing sheets .
- the grid connectors are preferably interlocking with fill holes and conduit holes for services.
- the angular roofing panel may further comprise perimeter elements having a channel to receive a bottom, sides or top edge of a facing board around the perimeter.
- the perimeter channel elements can be formed by an extrusion of steel, aluminium, polyethylene or as a fabrication of any suitable tensile or reinforced material.
- the perimeter channel elements may have pressed flanges to form a connection to engage internal honeycomb grid connectors on the perimeter of the angular roofing panel.
- Top and bottom facing sheets may have a pre-fi ⁇ ished outer face, or be adapted to be surfaced by manufactured board profiles eg. by roofing tiles profiles, metal roof profiles, Expanded Polystyrene shaped or other architectural profiles and shapes.
- the high density facing sheet may be cladded with metal roofing profiles, concrete tile profiles of any other conventional roof cladding.
- An aperture may be formed in the grid connector element and dimensioned to allow passage of one or both of structural or insulation materials, void forms, conduits and utility services such as plumbing, electrical lines and communication lines.
- the perimeter channels used on angular roof panel elements can be formed as an extrusion from steel, aluminium, polyethylene or as a fabrication of any suitable tensile or reinforced material.
- the perimeter channels used on angular roof panel elements may have pressed flanges to form a connection to engage internal honeycomb grid connectors on the perimeter of the panel.
- the angular roof panel element may comprise one or more "keyhole” locking elements. These may be simple connectors or may allow the angular roof panel elements to "click” and engage to connectors from wall panel elements.
- these angular roofing panel elements connect to the horizontal ceiling panel elements to create a hinged roof truss element.
- hinged truss elements Figure 30, Reference 30
- the angular roof panel element may be utilized in structural suspended roofing element.
- the bottom facing sheet may be used as the ceiling of the fevel below.
- Fig 1 shows a horizontal ffoor panel element in situ on a building site
- Fig 2 shows vertical wall panel elements being assembled
- Figs 3 shows vertical wall panel elements being connected together and assembled on horizontal floor panel elements.
- Fig 4 shows the addition of vertical wall panel elements and horizontal floor pane! elements.
- Fig 5 shows a single level house constructed from modular panels
- Fig 6 is a cross section of a three level house constructed from modular panels
- Fig 7 shows a vertical wall panel in elevation '
- Fig 8a shows the internal structure of a modular panel in elevation
- Fig 8b is a side elevation corresponding to Fig 8a
- Fig 8c is a plan corresponding to Fig 8a
- Fig 9 shows detail W of Ffg 8
- Fig 10 shows detail Y of Fig 8
- Fig 11 shows detail Z of Fig 8
- Fig 12 shows detail X of Fig 8
- Fig 13 is a cut away view of the panel of Fig 8
- Fig 14 is a cross section of a floor wall junction construction
- Fig 15 shows the foot of the wall of Rg 14 secured in a concrete (or simitar) footing
- Fig 16 shows a clip (Ref 11)securing reinforcing bar (Ref 12)in the foot of the wall
- Fig 17 is a cross section of an alternative perimeter floor and wall junction construction
- Fig 18 is a cross section of the junction of an internal floor and wall junction
- Fig 19 shows the junction of Fig 18 with a concrete (or similar) footing poured
- Fig 20 shows the junction of Fig 18 with concrete (or similar) poured in the junction
- Fig 21 is a cross section of the junction of three verticaf wall elements to a vertical structural member for a non corefill application.
- Fig 21a is a cross section of the junction of three vertical wall elements to a vertical structural member for a corefill application.
- Fig 22 is a crass section of a joist.
- Fig 22a is a side elevation of joist in Fig 22
- Fig 23 is a cross section of a composite structural joist.
- Fig 24 shows a horizontal floor panel element supported by a screw footing
- Fig 25 shows an alternative floor wall joining system
- Fig 26 shows the fastener detail of Fig 25
- Fig 27 illustrates the fastener head slotting detail of Fig 25
- Fig 28 is a cross section of a floor leveling screw jack
- Fig 29 shows the jack of Fig 28 mounted on a pier
- Fig 30 is an elevation of a modular roof and ceiling panel
- Fig 31 illustrates the erection of the panel of Rg 30
- Fig 32 is a typical house plan view showing roof panel setoutfrom the panels in Fig 30
- Fig 33 shows an alternative construction of Figure 12 which adds Reference 31.
- Fig 34 is a alternative of the panel construction of Fig 13
- Fig 35 shows dove tailing panel construction alternative
- Fig 36 shows dove tailing panel perimeter construction and Fig 37 shows a box beam construction with dovetail connections
- the bearing capacity of the ground may vary from site to site.
- a structural connection is required to connect the modular building system to the ground. These connection details will vary with site requirements.
- the construction of the modular building system (house or similar) in accordance with the present invention may adopt a modular floor panel 1 and reinforcing trench 2 in Fig 1.
- screw pile 20 in Fig 24 may be an alternative to reinforcing trench 2 in Fig 1.
- bored piers with jacks figure 29 may be used as alternative to reinforced trench 2, Fig 1.
- Modular wall panels 3 are then erected with their lower ends in trench 2 as shown in Fig 2 . Where no trench is required (Fig 24 and Fig 29), wall panel 3 is not engaged in trench 2.
- Wall panels 3 can connect by engaging key holes 5, with bolts 6 as shown in Fig 3.
- the building is extended by joining floor panels 1 and wall panels 3 as shown in Fig 4, or alternatively as shown in Fig 24 and 29. Accordingly a dwelling is assembled with panels 3 including with cut out sections to form doors and windows and modular roof panels 7 forming the roof as shown in fig 5. Multi storey dwelling as shown ⁇ n.Fig 6 can also be constructed from the same modular panels 1, suspended floor panel 1a, 3,7 and 7a.
- Panels 1, suspended floor panel 1a, 3, 7 and 7a may be prefabricated with high density board, or reinforced board.
- these panels are prefabricated from sheets of magnesium oxide board or similar which fs a low cost, high strength, insulating, fireproof material. It is water resistant, sound insulating and is easily machined and glued to form structural panels and beams.
- Fig 7 shows wall panels 3 which have been fabricated from high density board or similar with recesses to accommodate openings.
- Figs 8a to 13 Detailed fabrication of panels is shown in Figs 8a to 13 wherein internal honeycomb grid connectors 8 are slotted to interlock and are bonded to each other and to facing sheets 8a and perimeter channels 8b. Holes 9 are cut in honeycomb grid connectors 8 so that concrete or structural foam or insulating material can be poured into the panels for additional strength especially at junctions as described below.
- Fig 14 shows wall panels 3 attached to floor panels 1 which are leveled by screw jacks 10 shown in detail in Figs 28 and 29.
- the lower section of wall panels 3 have clips 11 shown in Fig 16 to hold lengths of reinforcing rod 12. Accordingly wall panels 3 are secured by pouring concrete footings in trench 2.
- Fig 17 shows concrete also poured through hole 13 into floor panel 1 and wall panel 3 to reinforce their junction and create a structural perimeter beam 13a.
- FIG 18 two floor panels 1 are shown attached to internal wall panel 3 and in Fig 19 concrete is poured through holes 13 to form a footing Fn trench 2. Concrete can also be used to fill the floor wall junction as shown in Fig 20.
- wall panels 3 are shown attached to vertical structural element 4 by bolts 6 screwed into ferrule 15. Again concrete can be poured into panels 3 to secure the wall post junction.
- Fig 21a wall panels 3 are shown attached to vertical structural element 4 by bolts 14 screwed into ferrule 15 for non structural applications.
- Flanges 16 and web 18 of joist in Fig 22 and 22a are also fabricated from high density board or similar.
- Figure 23 shows a composite joist with web 18 is reinforced with bonded steel sheet or similar 17 to increase structural strength.
- Web 18 may incorporate "dovetail” or teeth type profiles (Fig 35,36 and 37) to engage Web 18 with flanges 16.
- FIG 35, Fig 36 and Fig 37 shows a structural beam.
- the structural capacity is derived from the angular placement of the internal connectors which a bonded with dovetail and rebated connections to perimeter panels and facing sheets 8a.
- Figure 24 illustrates alternative construction method where screw pile 20 connects to Bracket 20 which connects floor panel 1.
- Wall panel 3 connects to floor panel 1 , thereby negating requirement for trench 2 and concrete reinforcing footing.
- Fig 25 illustrates an alternative fastener 21 for joining wall panels 3 to floor panels 1 which are fitted over nut 23 and lowered onto fastener 21 as illustrated in Fig 27 via key hole slots 5. Hex head tool 22 is then used to tighten nut 23 onto fastener 21 thus clamping panel 3 to panel 1.
- Fig 28 shows screw jack 10 which is adjusted by lever 24 which turns screw 25 in ferrule 26. Screw 25 rotates about spherical mount 27 which rests in trench 2 or is mounted on pile 28 as shown in Fig 29.
- Figs 30 and 31 illustrate how roof panels 7 are erected from ceiling panels 7a by rotating struts 30 and locked to form roof sections which span wall panels 3 and are joined in a continuous roof as shown in Fig 32. It will be obvious that roof panels 7 together with ceiling panels 7a form a sealed roof which also provides overhanging eaves.
- Figure 31 illustrates flat pack for ease of transport to site.
- Figs 33 and 34 illustrate an alternative panel construction in which honeycomb grid connectors 8 have lugs 31 which slot into mating slots in the facing sheets ⁇ aand perimeter edges 8b.
- Fig 35 illustrates a dove tail panel construction
- Fig 36 illustrates a dove tail connection method with slotted channel for panel edge reinforcement.
- Fig 37 illustrates a dove tail box beam construction.
- the modular panels are lightweight and are transported on site in flat pack form. Joining panels is a simple process which is done quickly and requires few tools. The provision of foundations and pouring of footings is simplified and concrete can also be used to fill panels to increase weight and strength especially at junctions. Accordingly high integrity building ratings can be achieved as are required for example in cyclone prone areas.
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- Life Sciences & Earth Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
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Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU2010256330A AU2010256330A1 (en) | 2009-06-03 | 2010-05-27 | Modular building system |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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AU2009902512 | 2009-06-03 | ||
AU2009902512A AU2009902512A0 (en) | 2009-06-03 | Modular building system |
Publications (1)
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WO2010138993A1 true WO2010138993A1 (en) | 2010-12-09 |
Family
ID=43297179
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/AU2010/000647 WO2010138993A1 (en) | 2009-06-03 | 2010-05-27 | Modular building system |
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AU (1) | AU2010256330A1 (en) |
WO (1) | WO2010138993A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8978342B2 (en) | 2012-06-15 | 2015-03-17 | Auburn University | Residential radiant barrier assemblies |
JP2017115400A (en) * | 2015-12-24 | 2017-06-29 | トヨタホーム株式会社 | Mat foundation |
EP4202137A1 (en) * | 2021-12-22 | 2023-06-28 | Klaus Eckelmann | Method for erecting a building and building created using the method |
Citations (10)
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US3397494A (en) * | 1966-04-04 | 1968-08-20 | Reynolds Metals Co | Building apparatus and method of making same |
AU546409B2 (en) * | 1983-10-20 | 1985-08-29 | Ron Allan Industries (Australia) Pty. Ltd. | Building panel |
US4894974A (en) * | 1988-07-05 | 1990-01-23 | Walter J. Jaworski | Structural interlock frame system |
JPH08260608A (en) * | 1995-03-23 | 1996-10-08 | Misawa Homes Co Ltd | Roof unit |
US5735090A (en) * | 1995-08-08 | 1998-04-07 | Papke; William | Modular foundation construction and method |
US5860262A (en) * | 1997-04-09 | 1999-01-19 | Johnson; Frank K. | Permanent panelized mold apparatus and method for casting monolithic concrete structures in situ |
US6082066A (en) * | 1996-04-26 | 2000-07-04 | Peter Mill | Modular building system |
US20050072097A1 (en) * | 2002-07-18 | 2005-04-07 | Holloway Wynn Peter | Building panel |
US20050204695A1 (en) * | 2002-03-01 | 2005-09-22 | Paul Blazevic | Building panel and construction method |
US20080016805A1 (en) * | 2006-07-19 | 2008-01-24 | Richard Walter | Truss lock floor systems and related methods and apparatus |
-
2010
- 2010-05-27 AU AU2010256330A patent/AU2010256330A1/en not_active Abandoned
- 2010-05-27 WO PCT/AU2010/000647 patent/WO2010138993A1/en active Application Filing
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3397494A (en) * | 1966-04-04 | 1968-08-20 | Reynolds Metals Co | Building apparatus and method of making same |
AU546409B2 (en) * | 1983-10-20 | 1985-08-29 | Ron Allan Industries (Australia) Pty. Ltd. | Building panel |
US4894974A (en) * | 1988-07-05 | 1990-01-23 | Walter J. Jaworski | Structural interlock frame system |
JPH08260608A (en) * | 1995-03-23 | 1996-10-08 | Misawa Homes Co Ltd | Roof unit |
US5735090A (en) * | 1995-08-08 | 1998-04-07 | Papke; William | Modular foundation construction and method |
US6082066A (en) * | 1996-04-26 | 2000-07-04 | Peter Mill | Modular building system |
US5860262A (en) * | 1997-04-09 | 1999-01-19 | Johnson; Frank K. | Permanent panelized mold apparatus and method for casting monolithic concrete structures in situ |
US20050204695A1 (en) * | 2002-03-01 | 2005-09-22 | Paul Blazevic | Building panel and construction method |
US20050072097A1 (en) * | 2002-07-18 | 2005-04-07 | Holloway Wynn Peter | Building panel |
US20080016805A1 (en) * | 2006-07-19 | 2008-01-24 | Richard Walter | Truss lock floor systems and related methods and apparatus |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8978342B2 (en) | 2012-06-15 | 2015-03-17 | Auburn University | Residential radiant barrier assemblies |
JP2017115400A (en) * | 2015-12-24 | 2017-06-29 | トヨタホーム株式会社 | Mat foundation |
EP4202137A1 (en) * | 2021-12-22 | 2023-06-28 | Klaus Eckelmann | Method for erecting a building and building created using the method |
Also Published As
Publication number | Publication date |
---|---|
AU2010256330A1 (en) | 2011-12-22 |
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